Job aiding apparatus

ABSTRACT

A display unit of a job aiding apparatus disposed in each of work stations displays a job detail display image for showing a job detail in each of the work stations and a job result display image for showing a job result of the job detail. The worker in each of the work stations can perform a job easily according to the job detail shown in the job detail display image, and can easily and accurately confirm the job result according to the job result in the job result display image.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a job aiding apparatus for assisting aworker in accurately and efficiently working on a workpiece based on jobdetails and job results displayed on a display unit and also allowingthe worker to make easy decisions about job results.

2. Description of the Related Art

Production lines for manufacturing products, such as automobiles, madeof a large number of parts have a plurality of work stations eachprovided with an assembly manual which describes a work procedure andthe numbers of parts assembled in the work station. The worker in eachwork station assembles desired parts by seeing the assembly manual.

Recent years have seen trends for the manufacture of many types ofproducts in small quantities to meet various needs of users. To minimizeinvestments in production facilities, one production line is suppliedwith mixed parts for a plurality of products of different kinds. Theworker in each work station of such a production line assembles partsaccording to different assembly manuals for the respective types ofproducts.

However, such a production process is disadvantageous in that theworkers cannot fully avoid errors in their job no matter how skilledthey may be. For example, the worker in each work station may assembleparts in a wrong sequence or may put together parts of differentproducts. Furthermore, in order to inspect a fastened bolt to see if thetorque with which the bolt has been tightened is in a predeterminedtorque range, the worker reads the torque value from a torque meter anddecides whether the torque value falls within the predetermined torquerange that is given in the assembly manual. At this time, the worker maymake an error in making such a decision.

There have heretofore been available an apparatus for displaying thevideo of a work procedure for the worker to avoid errors in the workprocedure, an apparatus for displaying inspection data on a display unitfor the worker to easily confirm the inspection data, and an apparatusfor reading a number inherent in a part from the part for the worker toprocess the part according to an instruction given on the basis of theread number.

These apparatus have been independent of each other. For example, a workprocedure is being displayed on a display unit, and the result of thejob done according to the work procedure is displayed on another displayunit. Therefore, since the worker is required to see both the displayunits, the work which the worker needs to perform is so complex that theworker tends to cause errors.

Even when these apparatus are employed, it is impossible to completelyget rid of errors. For example, when the worker tightens a plurality ofbolts on a workpiece and then measures and confirms the torque of eachof the bolts, the worker may measure the torque of one bolt a pluralityof times. When such a mistake takes place, because there is no way ofdetecting which bolt has been measured twice, all the bolts have to bemeasured again.

On production lines, workpieces are processed without being stopped atwork stations for higher production efficiency. Display units of thetype described above are positioned at spaced intervals along theproduction lines. Since, however, many various devices other than thosedisplay units are also positioned alongside of the production lines, thelayout of the display units is subject to significant limitations.Inasmuch as workpieces move downstream along the production lines, adisplay unit for displaying measured results in each work station needsto be located downstream of the other display units, so that the workerin each station can work on workpieces smoothly based on imagesdisplayed on the display units. This also poses a limitation on thelayout of the display units.

SUMMARY OF THE INVENTION

It is a principal object of the present invention to provide a jobaiding apparatus for allowing a worker to confirm job details and jobresults with ease to avoid errors in the job.

Another object of the present invention is to provide a job aidingapparatus for assisting a worker in accurately and efficiently workingon a workpiece.

Still another object of the present invention is to provide a job aidingapparatus which minimizes limitations on the layout of a display unitfor displaying job details and job results.

Yet still another object of the present invention is to provide a jobaiding apparatus which prevents a worker from making errors in themanufacture of many types of products in small quantities.

The above and other objects, features, and advantages of the presentinvention will become more apparent from the following description whentaken in conjunction with the accompanying drawings in which a preferredembodiment of the present invention is shown by way of illustrativeexample.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a portion of a production line whichincorporates job aiding apparatus according to the present invention;

FIG. 2 is a block diagram of the job aiding apparatus shown in FIG. 1;

FIG. 3 is a flowchart of an operation sequence of the job aidingapparatus shown in FIG. 1;

FIGS. 4 through 7 are views showing displayed job aid images forrecording an inherent part number;

FIGS. 8 through 10 are views showing displayed job aid images forinspecting a workpiece;

FIG. 11 is a view showing a displayed job aid image of a certain workingprocess at an enlarged scale;

FIG. 12 is a view showing a displayed job aid image of a certain workingprocess at a reduced scale;

FIGS. 13 and 14 are views showing displayed job aid images fortightening a bolt; and

FIG. 15 is a view showing a displayed job aid image for confirming a jobstate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows in perspective a portion of a production line whichincorporates job aiding apparatus according to the present invention. Asshown in FIG. 1, the production line has a first work station ST1 and asecond work station ST2 which is positioned downstream of the first workstation ST1 with respect to the direction in which workpieces flow alongthe production line. The first work station ST1 and the second workstation ST2 have job aiding apparatus 12A, 12B, respectively. WorkpiecesW are fed downstream along the production line by respective carriagecarts 10. In the first and second work stations ST1, ST2, the workpiecesW carried on the respective carriage carts 10 are processed byrespective workers M using tools 14, parts 16, etc. as instructed by thejob aiding apparatus 12A, 12B, respectively.

FIG. 2 shows in block form each of the job aiding apparatus 12A, 12B. Asshown in FIG. 2, each of the job aiding apparatus 12A, 12B includes adisplay unit 18 such as a CRT or the like for displaying job details,job results, etc. with respect to the workpiece W, an input device 20such as a keyboard, a bar-code reader, etc., a measuring unit 22, atester 24, video cameras 26, 28 (see also FIG. 1) for recording videoimages of job states, a switch 30 for manually operating the videocamera 26, 28.

Each of the job aiding apparatus 12A, 12B comprises a controller 32connected to the display unit 18, the input device 20, the measuringunit 22, the tester 24, the video cameras 26, 28, and the switch 30, animage capture unit 34 for capturing images through the video cameras 26,28, an ON/OFF signal processor 36 for processing ON/OFF signals from thetester 24 which detects whether there is a pressure leakage, etc. ornot, a measured data processor 38 for processing measured data producedby the measuring unit 22 associated with the tool 14, which may be atorque wrench or the like, an inherent number checking unit 40 forchecking inherent numbers of the workpieces W or the parts 16 which havebeen entered by the input device 20, an image display processor 42 fordisplaying images on the display unit 18, and a database processor 44.

Each of inherent numbers is expressed in a format “AA BBBBB ccc-dddd”where “AA BBBBB” indicates a product number and “ccc-dddd” indicates aninherent number of a workpiece W or a part 16. Specifically, if aproduct to be manufactured is a motor vehicle, then “AA” indicates thetype of the motor vehicle, “BBBBB” indicates the type of an engine orthe like mounted on the motor vehicle, “ccc” indicates a version numberof a workpiece W or a part 16 of the engine, and “dddd” indicates aninherent serial number of the workpiece W or the part 16.

To the database processor 44, there is connected a database file 46which stores a database of decision data for making decisions aboutmeasured data, a database of inherent number data for checking inherentnumbers of workpieces W and parts 16, and a database of image data to bedisplayed on the display unit 18. A parameter file 48 which storesparameters including addresses required for performing variousprocesses.

A work procedure to be carried out by a worker M using the job aidingapparatus 12A, 12B will be described below with reference to FIG. 3.

The image display processor 42 displays a job aid image 50 (see FIG. 4)on the display unit 18 according to a work procedure read from thedatabase file 46 by the database processor 44 in step S1.

The job aid image 50 shown in FIG. 4 serves to assist the worker M inrecording an inherent number of the workpiece W to be processed. The jobaid image 50 includes a job image display area 52 for showing a job tobe performed in the first work station ST1 or the second work stationST2, together with an image of the workpiece W, a process work displayarea 54 for showing a job detail, a quality control item display area 56for showing a quality control item, a data entry area 58 for entering aninherent number, and a data display area 60 for displaying an enteredinherent number.

In step S2, a process A is selected for recording an inherent number.

First, the worker M enters the inherent number, e.g., “01 HPDU0102-0123”, of the workpiece W transferred to the first work station ST1or the second work station ST2 according to the information displayed inthe process work display area 54 and the quality control item displayarea 56. The worker M may enter the inherent number that has beenassigned to the workpiece W, through either the keyboard or the bar-codereader.

The entered inherent number is displayed in the data entry area 58. Theinherent number checking unit 40 checks the entered inherent number tosee if it is proper or not in step S4. Specifically, the inherent numberchecking unit 40 decides whether a workpiece W having an inherent numbercorresponding to a product displayed in the job image display area 52has been delivered to the first work station ST1 or the second workstation ST2 or not by comparing high-order figures of the inherentnumber, e.g., “01 HPDU0” with inherent number data read from thedatabase file 46.

If the entered inherent number is determined as a proper inherent numbercorresponding to the workpiece W displayed in the job image display area52, then it becomes possible to point a key “Enter Input” . When theworker M points the key “Enter Input”, the inherent number is displayedin the data display area 60 in a job aid image 62 shown in FIG. 5, andrecorded in the database file 46 by the database processor 44 in stepS5. If the entered inherent number does not correspond to the displayedworkpiece W, then the key “Enter Input” cannot be pointed, indicating tothe worker M that the data has been entered by mistake or thetransferred workpiece W is improper.

When the proper inherent number is entered, it is decided whether thereis a next job in the first work station ST1 or the second work stationST2 or not in step S6. If there is a next job in the first work stationST1 or the second work station ST2, then a process for proceeding to anext job process is carried out in step S7, and then a job aid image 64shown in FIG. 6 is displayed in step S1. The job aid image 64 serves toprompt the worker M to enter the inherent number of a part 16 to beassembled on the workpiece W shown in FIGS. 4 and 5. Then, the worker Menters the inherent number in the same manner as described above.

The inherent number entered by the worker M is checked. Specifically,the inherent number checking unit 40 decides whether the workpiece Wcorresponds to the product by comparing high-order figures of theinherent number, e.g., “01 HPDU0” with inherent number data read fromthe database file 46. The inherent number checking unit 40 also decideswhether low-order figures of the inherent number, e.g., “234-1234”,overlap those of an inherent number already entered or not. If theentered inherent number is the same as an inherent number alreadyentered (with figures “234-1233” overlapping) as indicated by a job aidimage 66 shown in FIG. 7, then since the key “Enter Input” cannot bepointed, the entered inherent number cannot be recorded. The worker Mnow recognizes that the inherent number has been entered by mistake orthe part 16 assembled on the workpiece W is improper. The worker Mreenters a proper inherent number of a proper part in step S4.

As described above, it is checked whether the entered inherent numbercorresponds to a workpiece W displayed in the job image display area 52or the entered inherent number is the same as an entered inherent numberalready entered, so that a wrong process is prevented in advance fromoccurring.

After all inherent numbers have been entered, the display unit 18displays a job aid image 68 relative to a process B which is a next jobto be done, in step S1. In step S2, the process B is selected forinspecting the workpiece W.

The worker M inspects the workpiece W with the tester 24, for example,according to details displayed in the process work display area 54, thejob image display area 52, and a pressure leakage inspection displayarea 70 in the job aid image 68. An inspected result produced by thetester 24 is supplied as an OK/NG signal via the controller 32 to theON/OFF signal processor 36 in step S8.

If the inspected result indicates no pressure leakage (OK), then theletters “OK” displayed in the pressure leakage inspection display area70 are highlighted in a job aid image 72 shown in FIG. 9, indicating tothe worker M that workpiece W is free of a pressure leakage and that theworker M may go to a next job in step S9. When the worker M then pointsa key “Enter Next Job”, the job aid image 72 changes to a next job aidimage.

If the inspected result indicates a pressure leakage (NG), then theletters “NG” displayed in the pressure leakage inspection display area70 are highlighted in a job aid image 74 shown in FIG. 10, indicating tothe worker M that workpiece W suffers a pressure leakage and promptingthe worker M to inspect the workpiece W again. Since the key “Enter NextJob” (see FIG. 9) cannot be pointed, the worker M cannot proceed to anext process until the inspected result indicates no pressure leakage(OK).

After the workpiece W has been inspected, the display unit 18 displays ajob aid image 76 relative to a process C which is a next job to be done,as shown in FIG. H11, in step S1. In step S2, the process C is selected,and then a predetermined job is performed on the workpiece W in stepS10.

In the process C, the worker M coats the workpiece W with a compound,for example, according to a job air image 76 shown in FIG. 11 or a jobair image 78 shown in FIG. 12. In the process C, a process such as aninspection process is not carried out. As shown in FIGS. 11 and 12, thejob image display area 52 can be enlarged or reduced in size as desiredby the worker M for better working efficiency.

When the worker M points the key “Enter Next Job” after the process C,the display unit 18 displays a job aid image 80 relative to a process Dwhich is a next job to be done, as shown in FIG. 13, in step S1. The jobaid image 80 includes a data display area 82 for displaying a measuredvalue, a prescribed value which is an allowable value for the measuredvalue, and data to be recorded. In step S2, the process D is selectedfor tightening a part 16 on the workpiece W and recording a torque withwhich the part 16 is tightened.

First, the worker M tightens the part 16, which is a bolt, on theworkpiece W at a predetermined position according to an image displayedin the job image display area 52, measures the torque with which thebolt is tightened with the measuring unit 22, and supplies the measuredtorque through the controller 32 to the measured data processor 38 instep S11.

The data display area 82 displays the measured torque and an allowablerange for the measured torque. The measured data processor 38 comparesthe measured torque with data of the allowable range. If the measuredtorque does not fall within the allowable range, then the data displayarea 82 displays information indicating that the measured torque is nota proper torque, prompting the worker M to measure the torque again instep S12. If the measured torque falls within the allowable range, thenthe data display area 82 displays information indicating that themeasured torque is a proper torque, as indicated by a job aid image 84shown in FIG. 14. The measured torque is recorded in the database file46 in step S13. Then, a job air image relative to a next job isdisplayed in step S1. The job image display area 84 can also be enlargedor reduced in size as desired by the worker M for better workingefficiency.

Since the measured torque is automatically checked to see if it fallswithin the allowable range or not, the worker M is prevented from makingdecision errors. When the measured torque does not fall within theallowable range, the worker M can determine how far the measured torqueis from the allowable range, which may be used as a criteria formeasuring the torque again.

Because the job air images 50, 62, 64, 66, 68, 72, 74, 76, 78, 80, 84include the job image display area 52 and the data display areas 60, 82,70, which are displayed simultaneously, the worker M can perform jobsand confirm job details and job results while referring to the displayunit 81 only. Furthermore, the job image display area 52 displays animage of the workpiece W as viewed from the worker M. Therefore, theworker M is not required to mentally convert a displayed image forgrasping working spots as when the image is captured as viewed from theworkpiece W so as to include the worker M. Consequently, the worker Mcan easily and reliably perform jobs to be done.

On the display unit 18, job details are displayed upstream with respectto the direction of the production line, and job results are displayeddownstream with respect to the direction of the production line. Thisdisplay layout allows the worker M to confirm the job details andresults from an optimum position with respect to the workpiece W whichis moving downstream along the production line. For example, as shown inFIG. 14, the job image display area 52 is displayed upstream withrespect to the direction of the production line, and the data displayarea 82 is displayed downstream with respect to the direction of theproduction line.

The worker M tightens a bolt as a part 16 on the workpiece W at apredetermined position according to details displayed in the processwork display area 54 and the quality control item display area 56 in thejob aid image 84, while being assisted by a job detail image displayedin the job image display area 52. The worker M then measures the torquewith which the bolt is tightened, and supplies the measured torquethrough the controller 32 to the measured data processor 38. During thistime, the workpiece W is being transferred downstream. Then, thedownstream data display area 82 displays the measured torque and itsallowable range. The measured data processor 38 compares the measuredtorque with the allowable range. If the measured torque does not fallwithin the allowable range, then the measured data processor 38 displaysthat the measured torque is an improper torque, prompting the worker Mto measure the torque again. At this time, the worker M is movingdownstream with the workpiece W, and can confirm the job result imagedisplayed in the data display area 82 which is displayed in thedownstream region of the display unit 18.

If the job detail image displayed upstream of the job result image isalready unnecessary when the job result image is displayed, then onlythe job result image may be displayed at an enlarged scale on thedisplay unit 18. The worker M can confirm the job result easily based onthe enlarged job result image.

In the processes A-D described above, video images of job states may berecorded by the video cameras 26, 28, and may be played back in aplayback image display area 88 in a job aid image 86 shown in FIG. 15.The worker M may operate the switch 30 to capture a desired image forconfirmation.

In the process D, for example, a number of bolts need to be tightened,and their torques need to be measured. During the process D, the workerM may erroneously measure the torque of one bolt twice. If the worker Merroneously measures the torque of a bolt twice, then a process E isalso selected, and the torque measuring process is imaged by the videocameras 26, 28, and recorded by the image capture unit 34 in steps S14,S15. Thereafter, the recorded torque measuring process is displayed inthe playback image display area 88 to locate the wrong torquemeasurement, so that the worker M can take an appropriate correctiveaction. The video cameras 26, 28 are positioned for taking differentimages depending on workpiece locations to be processed, and canautomatically or manually be switched by the switch 30, depending on theworkpiece location where the worker M processes the workpiece W. Sincethe worker M processes only the erroneous job based on the image that isbeing played back, the worker M can perform necessary jobs highlyefficiently.

Although a certain preferred embodiment of the present invention hasbeen shown and described in detail, it should be understood that variouschanges and modifications may be made therein without departing from thescope of the appended claims.

What is claimed is:
 1. A job aiding apparatus comprising display meansdisposed near a working position of a worker, for displaying a jobdetail display image for showing a job detail yet to be performed on aworkpiece and after completion of said job detail by said worker butwhile said job detail display image remains displayed, displayingsimultaneously therewith a job result display image for showing acompleted job result of work performed by the worker in accordance withsaid job detail shown by said job detail display image.
 2. A job aidingapparatus according to claim 1, wherein said job detail display imagedisplays a job detail with respect to the workpiece as viewed from theworking position of the worker.
 3. A job aiding apparatus according toclaim 1, wherein said job detail display image can be displayed at anenlarged scale and a reduced scale.
 4. A job aiding apparatus accordingto claim 1, wherein said job result display image displays data of thejob result.
 5. A job aiding apparatus according to claim 4, wherein saiddata comprises an inherent number of the workpiece entered by the workeror an inherent number of a part used on the workpiece.
 6. A job aidingapparatus according to claim 4, wherein said data comprises measureddata.
 7. A job aiding apparatus according to claim 1, wherein said jobresult display image displays an image indicative of whether the jobresult is acceptable or not.
 8. A job aiding apparatus according toclaim 1, wherein said job detail display image is displayed upstream ofsaid job result display image on said display means with respect to aproduction line associated with the job aiding apparatus.
 9. A jobaiding apparatus according to claim 1, wherein said display means isdisposed in each of work stations of a production line associated withthe job aiding apparatus.
 10. A job aiding apparatus comprising: displaymeans disposed near a working position of a worker; and video recordingmeans for recording with a video camera a job state video image withrespect to a workpiece in the working position; said display meanscomprising means for displaying a job detail display image for showing ajob detail yet to be performed on the workpiece, after completion ofsaid job detail by the worker but while said job detail display imageremains displayed, displaying simultaneously therewith a job resultdisplay image for showing a job result of work performed by the workerin accordance with the job detail shown by said job detail displayimage, and displaying said job state video image recorded by said videorecording means.
 11. A job aiding apparatus according to claim 10,wherein said recording means comprises a plurality of recording meansdisposed in different positions, respectively, for recording images ofthe workpiece at different positions, respectively, thereon.
 12. A jobaiding apparatus according to claim 10, wherein said display meanscomprises means for displaying an inherent number of the workpieceentered by the worker or an inherent number of a part used on theworkpiece.